Unexpected machine startups or the release of stored energy during maintenance are among the leading causes of serious workplace accidents. To prevent these hazards, companies must strictly follow the lockout process—a proven safety system designed to protect workers. But what exactly are the steps? This guide explains the four main stages of lockout tagout procedures, why each one matters, and how using trusted solutions from Lockey company can ensure compliance and safety.
The lock out procedures in the workplace are not just guidelines—they are legal and safety requirements. OSHA and other international regulators mandate the use of lockout tagout procedures (often called the lototo procedure or loto steps) to prevent injuries caused by uncontrolled energy.
Hazardous energy sources include:
Electrical (wiring, circuits, motors)
Mechanical (moving parts, belts, gears)
Hydraulic and pneumatic (fluid or air pressure)
Thermal or chemical (heat, steam, gas, liquids)
Without a proper lock out tag out process, a worker servicing equipment could be exposed to deadly energy—even if the machine looks powered off. That’s why understanding the lock out tag out steps and applying them consistently is essential for compliance and safety.
Although some training manuals outline the 5 steps of lockout/tagout, all of them can be grouped into four main stages. These form the backbone of the lock out tag out procedure steps.
The first step in a lockout-and-tag procedure is preparation. Workers must:
Identify all energy sources connected to the equipment.
Review how to safely isolate each source.
Communicate with affected employees.
This is the answer to the question often asked in training: “What is the first step of the LOTO process?”
For example, a machine may not only use electrical energy but also compressed air. Failing to identify both could result in incomplete isolation. Preparation also includes determining how many locks are used in a group lockout process—ensuring every authorized worker attaches their personal lock.
After preparation, the next step is to stop the equipment using its standard shutdown procedure. Depending on the machine, this might involve:
Switching off power using a control button.
Turning a key to stop operations.
Closing valves to halt fluid or gas flow.
The goal is to bring the equipment to a complete stop before energy isolation begins. This is one of the most straightforward loto steps, but it must be performed carefully to avoid unexpected motion or partial shutdown.
3-3 Step 3: lsolate the Energy Sources
Once the machine is shut down, workers must isolate all sources of hazardous energy. This step in the lockout process may include:
Switching off and locking circuit breakers.
Disconnecting plugs from power outlets.
Shutting and locking valves for fluids or gases.
Blocking moving parts to prevent mechanical motion.
Each worker then applies their own lock and tag to the isolation point. This personal lock ensures that no one else can restart the system. The importance of this step is why many safety programs emphasize the lock out tag out process as a team responsibility.
3-4 Step 4: Verify Zero Energy (Final Step)
Verification is the most critical stage. Even after energy isolation, machines can hold residual or stored energy that must be released or blocked. Workers should:
Bleed off pressure in hydraulic or pneumatic lines.
Discharge capacitors in electrical systems.
Lower or secure elevated parts.
Test the start button or switch to confirm the machine cannot restart.
This directly answers the question: “What is the final step in lockouttagout?” The answer is always verify zero energy. Skipping verification can expose workers to hidden dangers, even when locks are in place.
Even the best-written lock out tag out procedure steps can fail without reliable equipment. Poor-quality locks and tags can break, be bypassed, or fail during audits. This is why choosing the right tools for the lock out tag out steps is as important as the procedure itself.
The Lockey company is a leading global manufacturer of lockout tagout devices. Their products include:
Electrical lockouts: circuit breaker lockouts, plug lockouts.
Valve lockouts: ball valve, gate valve, butterfly valve lockouts.
Lockout kits and stations: organized solutions for workplace compliance.
With Lockey Lockout solutions, companies ensure every stage of the lockout tagout process is backed by durable, OSHA-compliant devices.
The four main stages of the lockout process—prepare, shut down, isolate, and verify—are the foundation of safe maintenance. By following these loto steps consistently, companies protect workers, reduce accident risks, and maintain compliance. But procedures alone aren’t enough. The right lockout devices make all the difference. That’s why safety leaders worldwide trust Lockey company and Lockey Lockout products to deliver reliable protection in every situation.Don’t wait for an accident to highlight gaps in your system. Strengthen your lockout tagout procedures today with Lockey Lockout solutions and create a safer, compliant workplace for every employee.
